Electrical component and method for making the same

ABSTRACT

An electrical component ( 100 ) includes a housing ( 1 ), a number of terminals ( 2 ) molded within housing and at least one electrical element ( 3 ). The housing has at least a side wall ( 11 ) having a number of recesses ( 112 ) and an internal cavity ( 15 ). Each terminal has a first end ( 23 ) extending to a bottom of the side wall and formed with a platform portion ( 231 ) located onto the bottom of the side wall and aligned with the corresponding recess. The electrical element has a number of wires ( 321 ) wrapped thereon. One end of the wire extends outward the cavity through the recess and is soldered onto the corresponding platform portion.

This application is a continuation application of U.S. Pat. No. 7,948,771 to be issued on May 24, 2011.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an electrical component having a plurality of electrical elements adapted for being soldered onto a plurality of terminals and a method for producing the same.

2. Description of Prior Arts

U.S. Pat. No. 5,656,985 issued on Aug. 12, 1997 discloses an electronic component comprising a housing having a plurality of side walls, an open bottom and a cavity defined therebetween, a plurality of electrical elements located within the cavity and a plurality of pins molded into the side walls of the housing. The electrical element has a plurality of wires wrapped thereon. Each of the pins has a notched post upon which the wire is wound.

However, during assembling, it is difficult and time consuming to wind the wire upon the notched post.

Hence, it is desirable to provide an improved electrical element to overcome the aforementioned disadvantages.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an electrical component comprising a number of terminals and at least an electrical element having a plurality of wires effectively connected with the corresponding terminals. Another object of the present invention is to provide a method of easily assembly the electrical component.

To achieve the above object, an electrical component comprises a housing, a plurality of terminals embeded within housing and at least one electrical element. The housing has a top wall, at least a side wall having a plurality of recesses, an open bottom and an internal cavity. Each terminal has a first end extend to a bottom of the side wall and formed with a platform portion located onto the bottom of the side wall and aligned with corresponding recess. The electrical element comprises a plurality of wires wrapped thereon. One end of the wire extends through the recess and is soldered onto the corresponding platform portion.

During assembly, it is easy to solder the wires of electrical element onto the terminals if only locating the ends of the wires on the corresponding platform portions of the terminals.

Other objects, advantages and novel features of the invention will become more apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of an electrical component in accordance with the present invention;

FIG. 2 is perspective view of the electrical component, taken from another aspect;

FIG. 3 is a perspective view showing a housing of the electrical component;

FIG. 4 is a perspective view showing a terminal of the electrical component; and

FIG. 5 is a perspective view showing an electrical element of the electrical component.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Reference will now be made to the drawing figures to describe the present invention in detail. Referring to FIGS. 1-5, an electrical component 100 in accordance with the present invention comprises a housing 1, a plurality of terminals 2 embeded within the housing 1 and a number of electrical elements 3. Each electrical element 3 has a plurality of wires 32 wrapped thereon.

Referring to FIGS. 2 and 3, the housing 1 has a top wall 10, a pair of opposite side walls 11, 12, an open bottom (not labeled), a plurality of internal walls 151 forming a number of divided internal cavities 15 for receiving the electrical elements 3. A bottom surface 110 of the side wall 11 is provided with a depressed portion 111 and has a plurality of recesses 112 defined thereon.

Referring to FIGS. 2 and 4, the terminals 2 are molded within the side walls 11 and each terminal 2 has a first end 23 extending along a bottom of said side walls 11, a second end 22 extending outwardly form the side wall 11 and a holding portion 21 molded within the housing 1. The holding portion 21 has a bending portion 212 extending obliquely upwardly. The first end 23 bends from the bending portion 212 and forms a platform portion 231 located on the depressed portion 111 of the side wall 11 and aligned with corresponding recess 112. The width of the platform portion 231 of the first end 23 is greater than the width of the second end 22 and the holding portion 21. The platform portion 231 of the first end 23 is not in alignment with the second end 22.

Referring to FIGS. 1-5, in assembling the electrical component 100, firstly, the terminals 2 are assembled to the side wall 11 of housing 1 by insert molding. Secondly, said electrical elements 3 are mounted within said internal cavities 15 of housing 1. Thirdly, one end of wire 321 is routed through the recess 111 of the side wall 11 and located onto the platform portion 231 of the terminal 2. Finally, the ends 321 of the wires 32 are soldered to the platform portions 231 of the terminals 2.

In accordance with the present invention, the electrical elements 3 are magnetic cores. Understandably, the electrical element 3 could be made from other material.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. An electrical component comprising: a housing comprising a side wall having a bottom surface facing downwardly, and an internal cavity being recessed upwardly from the bottom surface; a plurality of terminals being held to the side wall, each terminal having a platform portion, said platform portion having a bottom surface exposed from the bottom surface of said side wall and facing downwardly; and at least one electrical element positioned within the cavity and having a plurality of wires wrapped thereon, one end of the wire extending outward from the internal cavity and across the bottom surface of the platform, and being soldered thereon.
 2. The electrical component as claimed in claim 1, wherein the platform has a top surface opposite to the bottom surface, said top surface being supported on the bottom surface of the side wall.
 3. The electrical component as claimed in claim 1, wherein the side wall forms a plurality of recesses between the cavity and the platforms, said ends of the wires being routed by the recesses to be aligned with corresponding platforms of the terminals.
 4. The electrical component as claimed in claim 3, wherein said side wall has a plurality of protrusions extending downwardly from the bottom surface of the side wall, the recesses being defined between the protrusions.
 5. The electrical component as claimed in claim 1, wherein the terminals are held by the housing along a row direction, each of the terminals having a holding portion for holding the terminal to the housing, the platform portion having a width greater than the holding portion in the row direction.
 6. The electrical component as claimed in claim 1, wherein the housing has two end walls jointly with the side wall defining the internal cavity, the end wall extending downwardly beyond the side wall and forming a step from the side wall.
 7. The electrical component as claimed in claim 1, wherein the end of the wire extends across the bottom surface of the platform only once.
 8. An electrical component for use with a printed circuit board, comprising: an insulative housing defining a plurality of side walls commonly defining an interior cavity therein; a plurality of terminals held in the side walls, each of said terminals defining a platform portion which is hidden on an underside of the corresponding side wall, and an outer end which is exposed outside of the housing for mounting to said printed circuit board; and an electronic components disposed in the interior cavity with wires wound thereon, wherein one outer end of each of wires is securely seated to the platform portion.
 9. The electrical component as claimed in claim 8, wherein the platform portions face downwardly for facing toward the printed circuit board, and the corresponding outer ends of the wires is secured on the corresponding platform portions thereunder for facing toward the printed circuit board.
 10. The electrical component as claimed in claim 8, wherein each side wall defines a depression in an underside to receive the corresponding platform portions. 